Static neutralization utilizing non-corroding ion dispensing tips

ABSTRACT

Apparatus for reducing static electricity comprises 
     (a) electrically conductive cable means having tips spaced therealong to dispense ions in response to voltage application to the cable means, 
     (b) the cable means defining cable extents each of which is flexible and includes elongated metallic extent to which voltage is applicable, 
     (c) and needles having shanks extending adjacent the cable metallic extent to make sideward electrical contact therewith so as to receive voltage application, the needles defining the tips openly exposed outwardly of the cable extents to dispense ions into the atmosphere near the cable means, 
     (d) at least certain of the needles having surfaces at said tips consisting of tungsten or tungsten alloy for dispensing positive ions without corroding.

BACKGROUND 0F THE INVENTION

This application is a continuation-in-part of Ser. No. 680,143, filedDec. 10, 1984, which is a continuation-in-part of Ser. No. 570,926,filed Jan. 16, 1984, which is a continuation-in-part of Ser. No.420,904, filed Sept. 21, 1982, which is a continuation-in-part of Ser.No. 369,925, filed Apr. 19, 1982, which is a continuation-in-part ofSer. No. 290,423, filed Aug. 6, 1981, which is a continuation-in-part ofSer. No. 259,503, filed May 1, 1981, which is a continuation-in-part ofSer. No. 241,684, filed Mar. 9, 1981, which is a continuation-in-part ofSer. No. 124,242, filed Feb. 25, 1980.

This invention relates generally to the provision of cable means withcorrosion resistant ion dispensing needles, located in zones fortreatment of work such as plastic articles, animals and edibles, andelectronics parts.

There is a need for low cost, efficient means to induce collection ofair-borne particles, and to suppress static build-up in certain articletreating zones (electric parts procution, plastic parts or materialproduction, paper rolling apparatus, surgical operating rooms, cleanroom assemblies, and circuit board fabrication, etc.). Prior iondispensing devices were not easily installable to conform to specialrequirements as to product shape, zone size, etc., and often did notachieve desired static neutralization contrary to expectations, also,ion dispensing needles which are positively charged tend to corrode,undesirably.

SUMMARY OF THE INVENTION

It is a major object of the invention to provide method and apparatus toachieve controlled neutralization or reduction of static charge on orassociated work, or to achieve controlled net positive or negative ionflux in area at or adjacent to work, and without detrimental needlecorrosion.

The apparatus in accordance with the invention basically comprises:

(a) electrically conductive cable means having tips spaced threalong todispense ion in response to voltage application to the cable means,

(b) the cable means defining cable extents each of which is flexible andincludes elongated metallic extent to which voltage is applicable,

(c) the needles having shanks extending adjacent the cable metallicextents to make sideward electrical contact therewith so as to receivevoltage application, the needles defining the tips openly exposedoutwardly of the cable extents to dispense ions into the atmosphere nearthe cable means,

(d) at least certain of the needles having surfaces at said tipsconsisting of tungsten or tungsten alloy for dispensing positive ionswithout corroding.

As will appear, the needles may consist entirely of tungsten or tungstenalloy with a precious metal, or such composition may be formed as alayer (as by plating, cladding, or other application) on a metal needle(stainless steel, copper, etc.); and the so formed needles may beemployed in a dual cable system one cable having positive voltageapplied thereto and to said needles, or a single cable carrying suchneedles may be employed.

As will appear, the cables are typically flexible so as to bend and fitin different work areas; and spacers may typically have grooves in whichthe first and second cables are retained in such close alignment thattips on the two flexible cables project in generally the same direction,i.e., toward the work area, up or down; and auxiliary cable means may beprovided, with controlled voltage application thereto, to enhance iontravel toward the work area to neutralize static. The cables may includecores consisting of wire strands penetrated by the needles.

As will appear, pairs of cables, each with ion dispensing tips, may belocated at adjusted distances from the work, the cables of each pairhaving adjusted separation and being respectively adapted to receivepositive and negative voltage application, the levels of which may becontrolled, all for the purpose of achieving static chargeneutralization or reduction at or adjacent the work. In addition, thespacing of the tips or needles on the cables is adjusted to achieve thatobjective.

Typically, groups of tips on the first cable of a pair are staggeredrelative to groups of needles on the second cable of that pair; and thetips are located in association with the spacers to achieve desiredbalance of positive and negative ions in the work zone toward which thetips project, or some excess of positive ions.

The needles may incorporate layer of metal on the tungsten, that layerbeing bondable (as by welding or soldering) to the cable metal; theneedles may have cores other than tungsten; those cores may be looselyexposed for bonding to the cable metal; and the needles may have pointedopposite ends, for purposes as will appear.

The invention enables static charge control in work zones, eliminationof dangerous arcing in such zones, and control of net ion flux in animalor poultry zones and in edibles smoke houses, and clean rooms to provideunusual advantages, as will appear, and extended needle life.

These and other objects and advantages of the invention, as well as thedetails of an illustrative embodiment, will be more fully understoodfrom the following specification and drawings in which:

DRAWING DESCRIPTION

FIG. 1 is a plan view of apparatus embodying the invention;

FIG. 2 is a section on lines 2--2 of FIG. 1;

FIG. 3 shows cable support; and FIG. 4 shows cables in an articletreatment zone;

FIG. 4 shows cables in an article treatment zone;

FIG. 5 is a perspective view showing a multiple cable and wire system;

FIG. 6 is an elevation showing the FIG. 5 system installed in a cleanroom;

FIG. 7 is a fragmentary elevation showing the FIG. 5 system installedabove a perforated, false ceiling;

FIG. 8 is like FIG. 7;

FIG. 9 is a plan view of cables retained by improved spacer;

FIG. 10 is an enlarged plan view of a spacer as shown in FIG. 9;

FIG. 11 is a section on lines 11--11 of FIG. 10;

FIG. 12 is a perspective view like FIG. 5, showing the FIGS. 9-11spacers, and voltage adjustment of the cables as well as of an auxiliarywire;

FIG. 13 is a sectional view of a modified cable and needle, and FIG. 14shows a modified needle;

FIG. 15 is an elevation showing coated needles bonded to a cable orwire;

FIG. 16 is a modified view, similar to FIG. 11;

FIG. 17 is an enlarged elevation showing a modified needle;

FIG. 18 is a section taken on lines 18--18 of FIG. 17;

FIG. 19 is a view like FIG. 18, showing a wire attached to the needle;

FIG. 20 is a view like FIG. 18, showing a modified section;

FIG. 21 is an enlarged view showing a double pointed needle composite;and

FIG. 22 is a section of a needle showing a modified composite.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, first and second cable means appear at 204and 206. Each cable includes an elongated conductive metal core 207, anda protective sleeve 208 of insulative, such as polypopulene orpolyethylene, material ion dispensing tips, as formed for example byneedles, are shown at 209 and 210. The tips project generally in thesame direction, as toward work areas 211 seen in FIG. 4, there beingwork elements 212 in such area, to be made static free.

The cable are typically flexible so they can be strung in straight orcurved lines or configuration. Note straight cable lengths 204a and204c, and curved lengths or bends 204b in FIG. 4. Also the cable pair204 and 206 has adjusted lateral separation characterized in that staticelectrically at or proximate the work is effectively reduced tonon-objectionable level or levels when positive and negative voltagesare applied to the respective cables. Note positive voltage source 212connected at 213 to cable 204, and negative voltage source 214 connectedat 215 to cable 206.

Spacers are provided as at 217 and located at selected positions alongthe cables to hold them at adjusted separation K. The latter istypically between 1/2 and 11/2 inches.

Such spacers are shown in the form of insulative plastic bars, havingtwo notches 219 at K separation to removably receive the cables,sidewardly, i.e. with snap-in reception. The notches are sized toreceive and firmly retain the cables, as shown in FIG. 19. The cablesare frictionally held against rotation and the needles or tips 209 and210 are held projecting in the same direction, despite the bending ofthe parallel cables to conform to room geometery, as at 204b.

Holders are provided to support the cable pairs at selected spacing fromenclosure structure. In the example, insulative plastic rods 220 aresuitable attached at 221 to the ceiling or wall of enclosure 222, andsupport the cables. FIG. 3 shows the rod 220 having a side notch at 223,to receive a cable 204 or 206 of a connected pair.

The dual cables 204 and 206 as described, may be employed for purposesas described above.

Adjustment of the positive and negative ion dispensation by the tipgroups 209 and 210 is also enabled to aid in achievement of substantialneutralization of static in work area. In this regard, note in FIG. 1that the tips 209 in cable 206 are sidewardly offset from a portion 204dof the cable 204 which contains no tips; and that tips 210 in cable 204are sidewardly offset from a portion 206d of the cable 206 whichcontains no tips. Also, spacers 217 divide such staggered groups 209 and210, as shown. Further, the tips or needles in each group can beselectively removed to reduce ion dispensation, to aid in achievingstatic neutralization. Thus, if there is an excess of + charge at aparticular location in the work area, one or more needles 210 or tipscarrying + charge and located closest to that area may be removed fromcable 104, thereby to aid in achievement of charge balance in the workarea. Alternatively needles 209 may be added to cable 206. The needlesmay be pulled from the cable, and re-inserted at will. Note in FIG. 2that the needles extend adjacent the sides of th cores 207, and held inthat position by the plastic sleeve.

Also in FIG. 1, perpendiculars 226 from cable 204 intersect tips 209,such perpendiculars spaced from tips 210, and perpendiculars 227 fromcable 206 intersect tips 210, such perpendiculars spaced from tips 209.

Tip protection means may also be provided (as shown in FIGS. 4a-4d,referred to above) on the cables 204 and 206.

From the above FIGS. 1-4 it will be seen that the method ofsubstantially neutralizing static electricity at work in an extendedwork zone (the work occupying only a local relatively small portion ofthat zone) involves the steps:

(a) dispersing into the bulk of the extended work zone including saidportion thereof both positive and negative ions,

(b) such dispersing carried out to substantially balance the positiveand negative ion content in that portion of the zone.

Also, both positive and negative ions are dispersed from a large numberof intermixed multiple points spaced about the extended zone.

Referring now to FIGS. 5 and 6, elements which remain the same as inFIGS. 1-4 are given the same numbers.

The system includes not only the first and second cable means or cable204 and 206, as before, but also auxiliary means spaced from the cablemeans in the general direction of ion flow or travel toward the work,such auxiliary means being at or near ground potential, and havingexposed electrically conductive surface extent. In the example, theauxiliary means comprises a bare wire 230, aluminum or copper forexample, which extends generally parallel to and below the cables 204and 206. It may be supported, for example, by the insulative plasticrods 220, as in a side notch 231 in each rod. The wire 230, grounded asat 232, is centered generally below the high voltage, positive andnegative cables 204 and 206, at a distance of between 3 and 12 inchestherefrom, the optimum distance being between 4 and 6 inches. It isfound that the grounded wire enhances static neutralization effect allthe way to the floor 233, including the area of the work 212 atdistances of 7-9 feet below the cables 204 and 206. Also, the secondcable 230 tends to balance the positive and negative field ionization,thereby improving the static neutralization--even to zero in many cases.In this regard, pairs of cables 204 and 206, and wires 230, aretypically separated by distance "d", which is 3-5 feet.

In FIG. 7, a false, electrically insulative, ceiling panel 240 extendsparallel to and below the structural ceiling 241, leaving a ceilingspaced 242 therebetween. Panel 240 is perforated at a large number ofrow and column locations, as at 252, to pass air as from space 242 intoa work zone 211. The perforations may taper downwardly, and have upperentrance diameters of about 3/4 inch and lower exit diameters of about5/16 inch. Cables 204 and 206 are suspended in space 242, as by plasticrods 220a, or other supports, to emit positive and negative ions viatips as referred to above. The ions then pass downwardly into zone 211via perforations 252. Ground wire 230 is suspended by panel 242 andplastic support rods 220b below cables 204 and 206. The ground wirehelps draw or attract the ions through the perforations 252. FIG. 8shows a panel 240a, like panel 240, below cables 204 and 206 and alsobelow ground wire 230. Floor 233 may be as at 247 to pass air and dustfrom space 211 to a filter 248 and return to space 242.

In FIGS. 9-12, the cables 304 and 306 correspond to cables 204 and 206,respectively in FIG. 5, and the auxiliary wire 330 corresponds to wire230 in FIG. 5. Rods 320 support the cables and wire as in FIG. 5. Wire330 is supplied with voltage as from source 350, which is adjustable,and cables 304 and 306 are supplied with voltage from sources 312 and314, which are adjustable. Typically, voltage from source 312 is morepositive than voltage from source 314, and is therefore shown as +,whereas source 314 is shown as -. See adjustment knobs 312a, 314aand350a. Voltage from source 350 may be neutral, (i.e. grounded), positiveor negative. The function of wire 330 is to enhance staticneutralization effect in the work area therebelow, as described in FIG.5.

The improved spacers 370 have elongated parallel grooves 340 and 341 inwhich the cable 304 and 306 are retained at locations and separationfrom one another characterized in that static electricity at orproximate the work to be treated is effectively reduced tonon-objectionable levels when the differential voltages are applied tothe cables 304 and 306. See in this regard the tips defined by needles309 and cables 304 and needles 310 on cable 306. The needles areassociated with the spacers, wherein the cables are gripped, so that thetips point in directionally controlled relation. The spacers are locatedalong the cables at spacing L which varies beteen 3-4 inches and 2 feet.Needles 309 are associated with spacers which alternate with spacersassociated with needles 310; and typically there are more needles 310per unit length of cable than there are needles 309. An example is shownin FIG. 9, wherein spacers 307a carry one positive needle each, on cable304, whereas alternate spacers 307b carry two needles, each, on cable306. Needles 310 normally are negatively charged.

FIGS. 9-12 also show the provision of the spacers or cable spreaders inthe form of molded plastic blocks 370 defining the parallel grooves 340and 341. Pressure is exerted on the sides of the cables in the blocks,to hold the cables in place. The grooves have sideward entrance channels340aand 341a, and enlarged interiors 340b and 341b communicating withthe channels, for reception of the cables, with pressurization. Thedepths of the grooves are sufficient that the tips of the needles 310are within channels 340a and 341a, to protect against snagging or injuryto other apparatus or person, especially when the cables are wound asduring storage or shipment.

In FIG. 13 the cable 404 comprises multiple electrical wire strands 405enclosed within insulative sheath 406. An electrically conductive needle407 has been pressed into and through the bundle of strands 405 (thecore) to spread apart at least some strands and to protrude at tip 407a.This construction enables rapid assembly of needles to the cable, andvery good electrical contact of the needles to the core. Also the needlepoint is preserved, and not blunted by solid core metal.

In FIG. 14, the modified needle 500 consists of a conductive metal core501 (copper for example) on which a tungsten or tungsten alloy layer 502has been applied, as by coating, cladding, plating, etc. The layerdefines the sharp tip or point 502a from which positive ions areemitted. A positive voltage source 504 is connected with the needle orits tip occurs, whereas, with non tungsten needles corrosion can anddoes occur. The layer 502 may alternatively consist of a metallictungsten alloy, as for example gold and tungsten, or platinum andtungsten, the weight % of tungsten being in excess of about 50%. Thecable core and sheath elements 405 and 406 are the same as in FIG. 13,the needle having been forced through the core to have good sidewardelectrical contact with the core. All the needles described above inFIGS. 1-13, and to which positive voltage is applied, typically have thetungsten or tungsten alloy construction of FIG. 14, or else a solidtungsten or tungsten alloy composition, throughout the needle. Typicalpositive voltages are between 5000 and 15,000 volts, DC. Singleconductors employing such needles are also contemplated (i.e. omittingthe companion negative needle cable).

In FIG. 15, a cable means metallic extent 600, which may be flexible (asfor example copper wire) is attached to multiple needles 601. Suchneedles include a layer 601a of conductive metal on a tungsten core601b, the metal layer being bondable (as by soldering or welding at 602)to the wire 600. The tungsten is employed to resist corrosion, asbefore. Thorium coated, tungsten tips, appear at 603, for dispensingions.

FIG. 16 shows the provision of needles 611, the opposite ends of whichare pointed. The needles project through cables 404, as described above,and including multiple electrical wire strands 405 enclosed withininsulative sheaths 406. Needle points 611a project within groovechannels 340a and 341a, to dispense ions. Plastic spacer 370 defines thegrooves and channels, as before. The needle points 611b are pushed intothe cables, and may or may not penetrate the material of the spacer.They enable easy replacement of the needles, if desired, since theyeasily penetrate the wire strand bundle, when pushed in, and the needlesmay be easily withdrawn. Such needles may otherwise have theconstruction of any of the needles described in this specification.

FIGS. 17-19 show a modified needle 631 having a non-tungsten core 631aand a thin tungsten layer 631b or coating thereon. Core 631a may forexample, consists of steel, aluminum, copper, or alloys thereof, oraluminum alloy or other conductive and solderable (bondable) metal. Thecore has a locally outwardly exposed portion 631a' directly electricallybonded to the cable means or wire 600, as seen in FIGS. 17 and 19, asoldered area indicated at 624. Portion or flat surface 631a' may beformed as by grinding the needle end, as shown. The wire 600 is shown aslooped about the needle upper portion. In FIG. 20 two ground flats areformed as at 631c and 631d, and at different angles, to intersect andform an edge 631e that sharply engages and may slightly penetrate thewire 600 wound tightly thereon, for good electrical contact.

In FIG. 21 a modified needle 641 has a core 641a (which may consist ofsteel), a first tungsten coating 641b and a second thorium coating 641c,and to which a wire 600 may be easily soldered. The double pointedneedle has one pointed end portion 642 not coated with thorium, i.e. thetungsten point 647 is exposed to disperse ions, and not corrode. Theother pointed end portion 643 is thorium coated. In FIG. 22, themodified needle 651 has an all tungsten core 651a, and thorium coating651b thereon.

Positive or negative voltage may be applied to the FIGS. 15-22 needles.

I claim:
 1. In apparatus for reducing static electricity in a work zone,the combination that includes(a) electrically conductive cable meanshaving tips spaced therealong to dispense ions in response to voltageapplication to cable means, (b) the cable means defining cable extentseach of which is flexible and includes elongated metallic extent towhich voltage is applicable, (c) and needles having shanks extendingadjacent the metallic extent to make sideward electrical contacttherewith so as to receive voltage application, the needles defining thetips openly exposed outwardly of the cable extents to dispense ions intothe atmosphere near the cable means, (d) at least certain of the needleshaving surfaces at said tips consisting of tungsten or tungsten alloyfor dispensing positive ions without corroding.
 2. The combination ofclaim 1 including a layer of metal on said tungsten, said metal layerbeing electrically conductive and bondable to said cable means.
 3. Thecombination of claim 2 wherein said metal layer consists of thorium. 4.The combination of claim 1 wherein said needles have tungsten cores. 5.The combination of claim 1 wherein said certain needles have metalliccores other than tungsten, and have a tungsten layer thereon.
 6. Thecombination of claim 5 wherein said metallic cores consist of steel. 7.The combination of claim 5 including a layer of metal on said tungsten,said metal layer being electrically conductive and bondable to saidcable means.
 8. The combination of claim 7 wherein said metal layerconsists of thorium.
 9. The combination of claim 1 including a positivevoltage source electrically connected with said cable extents to providepositive voltage to said certain needles.
 10. The combination of claim 1wherein said cable means has multiple wire core extents, and said needleshanks are pushed through the core extents to have opposite sides inforcible engagement with said core extents.
 11. The combination of claim1 wherein the needles have pointed opposite ends.
 12. The combination ofclaim 5 wherein said cores have locally outwardly exposed portions forelectrical bonding to said cable means.
 13. The combination of claim 12wherein the locally outwardly exposed portions are flats.
 14. Thecombination of claim 13 wherein said flats are characterized by one orboth of the following:(i) a single flat on a needle (ii) two flats on aneedle and intersecting at an edge adapted to firmly grip said cablemeans.
 15. In apparatus for reducing static electricity in a work zone,the combination that includes(a) first electrically conductive cablemeans having tips spaced therealong to dispense positive ions inresponse to positive voltage application to the first cable means, (b)second electrically conductive cable means having tips spaced therealongto dispense negative ions in response to negative voltage application tothe second cable means, and (c) said cable means located at adjustedseparations from one another characterized in that static electricity ator proximate the work is effectively reduced to non-objectionable levelswhen said positive and negative voltages are carried to the cable means,(d) there being spacers located along the lengths of the cable means andholding the cable means at said adjusted separations, (e) said cablemeans defining cables each of which is flexible and includes andelongated metallic core to which voltage is applicable, the cableincluding a protective sleeve of insulating material on and extendingalong and about the core, the sleeve defining a wall, (f) and needleshaving shanks penetrating through said sleeve wall and extendingsidewardly adjacent the core to make electrical contact therewith so asto receive application of said voltage, the needles defining said tipsopenly exposed outwardly of the cable to dispense ions into theatmosphere near the cable, (g) said tips associated with the first andsecond cable means consisting of tungsten alloy, (h) said needles havingpointed opposite ends.
 16. The apparatus of claim 15 wherein certainpointed ends are located proximate the edge of said cable means.
 17. Thecombination of claim 15 including a layer of metal on said tungsten,said metal layer being electrically conductive and bondable to saidcable means.
 18. The combination of claim 17 wherein said layer consistsof thorium.
 19. The combination of claim 15 wherein said needles havemetallic cores other than tunsten, and have a tungsten layer thereon.20. The combination of claim 19 wherein said cores have locallyoutwardly exposed portions for electrical bonding to said cable means.21. The combination of claim 20 wherein the locally outwardly exposedportions are flats.
 22. The combination of claim 21 wherein said flatsare chareacterized by one or both of the following:(i) a single flat ona needle (ii) two flats on a needle and intersecting at an edge adaptedto firmly grip said cable means.
 23. The combination of claim 15including positive and negative voltage sources electrically connectedwith said respective cable means.
 24. The combination of claim 6 whereinsaid needle shanks are pushed through the core extents to have oppositesides in forcible engagement with said core extents, one pointed end ofeach needle also pushed into the spacer.
 25. The combination of claim 24wherein each cable means includes a non-metallic sheath on the coreextents.
 26. Needles having shanks adapted to extend adjacent themetallic extents of cable means to make sidewardly electrical contacttherewith so as to receive voltage application, the needles definingtips openly exposed outwardly of the cable extents to dispense ions intothe atmosphere near the cable means, at least certain of the needleshaving surfaces at said tips consisting of tungsten or tungsten alloyfor dispensing ions without corroding.
 27. The combination of claim 26including a layer metal on said tungsten, said metal layer beingelectrically conductive and bondable to said cable means.
 28. Thecombination of claim 27 wherein said metal layer consists of thorium.29. The combination of claim 26 wherein said needles have tungstencores.
 30. The combination of claim 26 wherein said certain needles havemetallic cores other than tungsten, and have a tungsten layer thereon.31. The combination of claim 30 wherein said metallic cores consist ofsteel.
 32. The combination of claim 30 including a layer of metal onsaid tungsten, said metal layer being electrically conductive andbondable to said cable means.
 33. The combination of claim 32 whereinsaid metal layer consists of thorium.
 34. The combination of claim 30wherein said cores have locally outwardly exposed portions forelectrical bonding to said cable means.
 35. The combination of claim 34wherein the locally outwardly exposed portions are flats.
 36. Thecombination of claim 35 wherein said flats are characterized by one orboth of the following:(i) a single flat on a needle ii) two flats on aneedle and intersecting at an edge adapted to firmly grip said cablemeans.
 37. The combination of claim 11 including spacers having groovesinto which the cable means is received, the one pointed end each ofselected needles pushed into the cable means.